Lenticular Array Wet Coating for 3D Display Alignment
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Solution Overview
Problem
Existing 3D electronic displays face issues with misalignment of lenticular arrays and pixels due to warping during the lamination process, leading to signal loss and reduced optical quality.
Innovation Solution
A wet coating process is used to apply a lenticular array onto a display element, with optical alignment techniques such as camera detection of markings to ensure precise alignment, and embossing with rollers or stamps to form the lenticular structures within the lacquer layer, maintaining alignment within 5 microns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a lamination process is used to form the lenticular array, then the manufacturing process is simple, but the lenticular structures become misaligned with the pixels due to warping
Solution Approach 1:
The patent applies a wet coating of lacquer to the display element before the lenticular array is formed. This preliminary coating creates a stable, non-warping substrate that allows for precise optical alignment and embossing of the lenticular structures, ensuring accurate alignment with the pixels below while maintaining manufacturing simplicity
Solution Approach 2:
The patent changes the physical state and properties of the coating material by applying it as a wet lacquer that can be embossed, then cured to form a stable structure. This parameter change allows the material to be shaped precisely during manufacturing while maintaining dimensional stability in the final product, preventing warping and alignment issues
2Ease of manufacture
If the plastic film is heated or cured during lamination, then the lenticular array is formed, but the film warps, shrinks, or expands causing misalignment
Solution Approach 1:
The patent uses a wet coating of lacquer that is applied in a liquid state, then embossed while in this state, and finally cured to form the stable lenticular structures. This parameter change from liquid to solid state allows for shaping without the warping and dimensional instability that occurs when plastic films are heated during lamination
Solution Approach 2:
The wet lacquer coating acts as an intermediary material between the display element and the final lenticular array. This intermediary can be precisely aligned and embossed before curing, providing a stable base that prevents the warping and dimensional changes that would otherwise occur with direct plastic film lamination
3Manufacturing precision
If alignment tolerances are kept within 5 microns, then optical quality is improved, but the alignment process becomes more complex
Solution Approach 1:
The patent replaces complex mechanical alignment systems with optical alignment techniques. A camera or other optical device is used to detect markings on the display component and embossing plate, automatically determining their relative positions and enabling precise alignment within 5 microns without complex mechanical positioning systems
Solution Approach 2:
The patent uses optical copying and detection methods where a camera captures images of markings on both the display component and embossing plate. This optical copying approach allows for precise measurement and alignment calculation, achieving sub-5-micron accuracy while simplifying the overall alignment process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method improves the optical quality and stability of the 3D display by ensuring accurate alignment of lenticular structures with pixels, enhancing user experience and reducing manufacturing defects.
Implementation Method 1
applying a wet coating of lacquer to a display component
Implementation Method 2
embossing a configured lenticular array into the wet coating or layer of lacquer
Implementation Method 3
The lacquer may then be UV cured or heat cured to harden or cure the lenticular lenses or structures
Data Source
AI summary
Describe herein are electronic devices that includes a display stack having a display component configured to display a three dimensional image. In some instances, the display component includes a layer of lenticular structures or lenses formed by applying a layer of liquid lacquer to a surface associated with the display component, embossing the lenticular structures into the lacquer, and curing or hardening the lenticular structures in place.